Paper documents and evening keying left book stock adrift. Receiving, putaway, picking and checking merged into one scan flow, with stock updated live.
The client is a regional distributor of fast-moving consumer goods handling several hundred outbound orders a day in cartons. Receiving was on paper with one batch entry before the shift ended, picking relied on memory, and nothing was checked before dispatch.
Three problems followed at once: book stock and physical stock disagreed, new staff had to ask where goods were, and a wrong shipment was only discovered when the customer complained.
Equipment and consumables commonly used in this scenario, configurable to your site.
Zebra ZT411 industrial printer with a 4.3-inch colour touchscreen, up to 600 dpi and redundant interfaces, for mid-size lines and warehouse traceability.
Datalogic Skorpio X5: enterprise Android, octa-core Qualcomm, IP65 sealing and a 4-inch display, for warehouse, manufacturing and retail data capture.
Zebra ZD421 desktop printer with flexible interface options, covering office, retail and light industrial labelling.
Datalogic PowerScan 9100 industrial scanners, built to last, with medium and long-range 1D reading for warehouse, manufacturing and logistics.
Datalogic AV500 and AV900 high-end fixed-mount vision readers that handle attended or unattended lines and read reliably on fast conveyors.
Custom adhesive labels in coated paper, synthetic, PET and matte silver, in custom sizes and winding, with sample print trials before bulk orders.
Based on the site conditions, we delivered the following custom solution.
The project began with bin coding in four segments of zone, row, column and level, printed on scratch-resistant labels for the rack beams. Without bin codes neither pick sequencing nor putaway binding is possible. It is the cheapest step and pays back immediately.
Receiving scans cartons and accumulates quantity with variance reasons selected on the spot. Putaway binds the item to a bin. Pick tasks reach the handheld in bin sequence, scanning bin then item and stopping on a mismatch. Loading checks every carton and flags over-shipment or short-shipment.
Fixed-mount scanners on the dock lane read the load as the forklift passes, with light and sound indication, so verification needs no stop. This turned the step most often skipped into one that completes automatically.
The terminal sequences work by bin location, so a new starter does not need to memorise the layout. Of all the changes, this is the one the client reported most directly: training dropped from two weeks to a few days.
Fixed-mount readers at the dock because a pallet is bulky and the operator has no free hand; handhelds between racks because aisles are narrow and scanning happens while walking. Both share one coding rule, so the back office sees a single stock record.
Location codes are pre-printed rather than handwritten so the system can sequence the pick path. Waves are cut by delivery route, which makes the pick order on the terminal the loading order and removes a sorting step.
Key steps and engineering details from the deployment.
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From device selection and label matching to system integration, tell us what you need and an engineer will prepare a plan.